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LEO Instructions

Edition:

01/2016

- Revision:

01/16

0 - 01

Contents

Chapter-Page

1 - General information and Warnings

Symbols in the manual

1-01

Contents and purpose of the manual

1-02

Required operator qualifications

1-03

Machine manufacturer identification data and location of CE nameplate

1-04

Facsimile CE declaration of conformity

1-05

General notes on delivery - Testing procedure - Warranty

1-06

Safety recommendations

1-07

Operating modes

1-09

Set-up by the customer

1-11

Service requests

1-11

2 - SAFETY

General information - Personal protective equipment to be used

2-01

Personal protective devices to be used

2-02

Signal plates - Hazards and residual risks

2-03

Function of the EMERGENCY button

2-05

3 - Machine Description

LEO Pallet Wrapper Robo description - Reasonably foreseeable misuse

3-01

Main parts of the machine - Specifications

3-02

Command and controls

3-03

4 - Machine Installation

Machine unpacking - Ground movement and positioning

4-01

Battery charging -

Robot ignition 4-02

Driving the robot - Film roll assembly

4-03

Film feeding - Film tension adjustment

4-04

5 - Using the Machine

Preliminary settings from control panel - Language change - Program setting

5-01

Program parameters change

5-02

Error messages

5-03

Operations 5-04

EMERGENCY intervention

5-06

Film tension adjustment - Switching off the robot

5-07

6 - Machine maintenance

Safety precautions - Qualification of maintenance personnel

6-01

General cleaning - Cleaning of carriage driving wheels

6-03

Safety equipment check

Motor check

6-04

Luminous and acoustic signal - Ground discharge - 40A Fuse efficiency check

6-05

Adjustment of the proximity - Photocell adjustment and efficiency check

6-06

Troubleshooting

6-07

7 - Demolition and disposal of the machine

7-01

Annexes

Warranty -

Service request form - Form for ordering replacement parts -

Electrical diagrams -

CE Declaration of Conformity

Summary of Contents for Leo

Page 1: ...10 POGLIANO MILANESE MI Italia Tel 39 02 9396461 r a Fax 39 02 93549494 www italdibipack com info italdibipack com Original Instructions in ITALIAN Edition 01 2016 Revision 01 16 CAUTION Read carefully before use Keep this Instruction Manual intact for future consultation L E O ...

Page 2: ...le misuse 3 01 Main parts of the machine Specifications 3 02 Command and controls 3 03 4 Machine Installation Machine unpacking Ground movement and positioning 4 01 Battery charging Robot ignition 4 02 Driving the robot Film roll assembly 4 03 Film feeding Film tension adjustment 4 04 5 Using the Machine Preliminary settings from control panel Language change Program setting 5 01 Program parameter...

Page 3: ...fies a hazard with risk of injury to the user including death Pay the utmost attention to text marked with this symbol Caution Denotes a warning of possible damage to the machine or other property of the user Warning Note Identifies a warning or note concerning key functions or useful information Additional information Text containing additional information is preceded by this symbol This informat...

Page 4: ...right to make changes to the instruction manual without notice Any change addition or removal of machine elements components functions or cycles carried out without prior agreement with ITALDIBIPACK S p A automatically releases the manufacturer from all liability This manual is dedicated to the machine user and maintenance technician with the aim of informing them of the main technical data and pr...

Page 5: ...forced stoppage Maintenance Mechanic Qualified technician able to run the machine in normal conditions to run it with the protections disabled to work on mechanical parts to perform adjustments maintenance operations and any repairs that may be needed The maintenance mechanic is not authorised to work on live electrical systems Maintenance Electrician Qualified technician able to run the machine i...

Page 6: ... The CE plate is affixed to the machine column as shown below and alongside and it bears indelible information concerning the machine CE MARK The related CE DECLARATION OF CONFORMITY is included in the annexes It is prohibited to remove the CE MARK plate and or exchange it with the plates of other machines of the same model supplied to the customer or operator If the CE MARK plate becomes damaged ...

Page 7: ...chine Name Model Serial number Year of Manufacture to which this declaration refers is compliant with the following European Directives and Harmonised Standards 2006 42 EC Machinery Directive and related national implementation provisions 2004 108 EC Electromagnetic Compatibility Directive EN ISO 12100 2010 Safety of machinery General principles of design Risk assessment and risk reduction EN 6020...

Page 8: ...cifications There is no visible damage due to transport or other causes In the case of damage or missing parts inform the shipping agent or ITALDIBIPACK S p A immediately and provide a detailed account of the damage FOR ALL REQUESTS TO ITALDIBIPACK S p A OR OUR SERVICE CENTRES ALWAYS QUOTE THE MACHINE TYPE SERIAL NUMBER AND YEAR OF PRODUCTION Testing procedure The machine is tested by the manufact...

Page 9: ...ne A machine is a functional unit composed of drive system work unit work and standby equipment technical systems electric pneumatic hydraulic lubricating and any supplementary assemblies to complete the functional performance of the plant 4 Work zone A work zone is a protected volume delimited by safety guards and designed to be in operation when the machine is running 5 Authorised personnel Auth...

Page 10: ... at working speed in the protected space with safety guards in their closed position and starting from the main pushbutton panel 12 Machine management Machine management is the set of operations that the person in charge must carry out to allow proper execution of the work process 13 Decommissioning Decommissioning is the mechanical and electrical removal of the machine from the production environ...

Page 11: ...ck that the control unit components are intact Check the consistency between the power supply voltage indicated on the CE plate and the voltage value of the mains distribution network Check that the safety guards are properly installed and perfectly efficient Press the EMERGENCY button A to stop the machine in emergency situations The machine safety is not guaran teed if its safety device B is rem...

Page 12: ... proper operation in the case of failure they must be immediately repaired or replaced The unauthorised use of commercial parts and accessories forming part of the safety devices and protections may cause malfunctions and give rise to hazardous situations for the operat ing personnel 1 10 Maintenance and repair Maintenance troubleshooting and repair are only permitted to authorised personnel Insta...

Page 13: ... circuit breakers earthing systems safety valves etc provided for by the legislation in force in the country of installation earth system compliant with Standard IEC 64 8 adequate lighting compliant with Standard EN 60204 1 CAUTION The machine is not equipped with a standard lighting system The ambient level of lighting must always be such to avoid shadow cones and ensure operation in the highest ...

Page 14: ...E REQUEST FORM enclosed with this manual Contact your nearest service centre or our headquarters in Italy Ordering spare parts Through time certain parts of the machine subject to wear will require replacement Customers can order any replacement parts required You must install exclusively genuine original parts When ordering spare parts please ensure you specify the following as clearly as possibl...

Page 15: ... or more machine parts the adoption of accessories that modify the use of the machine and of processing materi als other than those recommended in this manual may be cause of risks of injury SAFETY General information Hazards and residual risks General information All areas at risk have been evaluated during the project phase and therefore all necessary precautions have been taken to avoid risks t...

Page 16: ...e machine it is necessary to wear protective equipment suitable for the operations to be performed Clothing must be tight on the body In order to prevent mechanical risks such as dragging trapping and other risks IT IS COM PULSORY not to wear accessories such as bracelets watches rings or chains during main tenance operations requiring work to be performed with the area operational CAUTION Before ...

Page 17: ...and on yellow background Prohibition Round shape with black writing on white background red circular band and tilted Obligation Round shape with white writing on blue background SAFETY Do not transit or stand beneath the machine during movements Danger of crushing the fingers hands or foots Danger of dragging the fingers or hands HAZARDS and RESIDUAL RISKS Residual risk of electric shock Fig 1 Thi...

Page 18: ...the side Residual risk of crushing the fingers or hands Fig 2 The risk may be caused by leaving your fingers between the structure and the movable part Be very careful during machine move ment The Hazard Signal is applied on the film holder as indicated in the figure at the side HAZARDS and RESIDUAL RISKS SAFETY 2 04 3 2 Residual risk of dragging the fingers or hands in the chain Fig 4 The risk ma...

Page 19: ...ubsequent commissioning The electrical maintenance technician must verify the type of failure on the compo nents NOTE To reset the emergency stop function turn the mushroom shaped button in the direction of its arrow and reset the safety conditions by pressing ESC button on the control panel to resume the production cycle 2 05 SAFETY 5 CAUTION If for any reason the emergency button does not block ...

Page 20: ...m height of 2000 Limits of use The electrical equipment works properly within the ambient temperature limits between 5 C and 40 C and relative humidity limits not beyond 50 at 40 C and not beyond 90 at 20 C The machine is not suitable for operation in the presence of ionizing radiations and non X rays Laser Microwave UV rays The machine must be stored at temperatures between 5 C and 55 C Reasonabl...

Page 21: ...t with mechanical stretch or motorised pre stretch of film 10 Touching arm for machine rotation around the pallet 11 Foot guard front device Specifications Machine dimensions L x W x H Machine weight Battery power supply Socket power supply for battery charger Traction system with 2 motors Film roll holder carriage with chain driven by 1 motor Up down speed Fixed mast max wrapping height Minimum p...

Page 22: ...n machine ignition and switch off 5 START Button cycle start 6 ENTER Button enter settings 7 ESC Button exit settings and reset error messages 8 6 program selection and storage buttons Figure 7 1 Switch ON OFF key 2 Front back movement button 3 Right and left movement button works only during the front back movement 4 Emergency button Figure 9 1 3 LED battery status indicator GREEN battery charged...

Page 23: ...led and se cured to the pallet with appro priate strapping Cut the strap to free it from the pallet Ground movement and positioning To lift and move the machine still positioned on the pallet insert a Ø 20 mm bar in the hole indi cated by the arrow in Figure 12 and lift it using a forklift as indicated in Figure 12 INSTALLATION Machine unpacking a CAUTION The machine must be lifted and handled by ...

Page 24: ...r of the film roll holder carriage 15 Battery charging The machine is delivered with the batteries already charged To check the state of charge turn on the machine and wait for the display to shows under the number of program in use BATTERIA BAT TERY with the voltage value at the side To charge the batteries insert the supplied ca ble in the appropriate socket Fig 13 on one side and to a 110 240 V...

Page 25: ... Pos C buttons start moving the machine in all directions 3 NOTE The right left keys do not perform any action if one of the two forward backward keys are not pressed at the same time Operator protective device In case the reversing machine touches the operator the red key Fig 16 Pos B would be pressed stopping the machine immediately Film roll assembly Figure 17 shows the usable film roll measure...

Page 26: ...and therefore it should never be excessively tightened since it is NOT needed to restrain it Film feeding Run the film path as shown in the following diagrams The film roll can be inserted so that it unwin ds by rotating clockwise or anti clockwise in rela tion to the sticky side of the film INNER glue Clockwise unwinding OUTER glue anti clockwise unwinding Film holder with mechanical stretch A B ...

Page 27: ...mi tempi lingua programs times language Press to move the cursor in correspondence of lingua lan guage Press or to move the cursor in correspondence of the want ed language Press ENTER to confirm the operation and then ESC to exit the screen Program setting Using the controls it is possible to set the wanted operating param eters and store them in 6 different work programs The following can be sto...

Page 28: ...Z V Not modifiable Value 99 VERTICAL V Modifiable it is the up and down speed of the film roll holder carriage Changing the value the overlapping of the film increases or decreases Recommended value 90 Pressing twice the following increases or decreases words appear on the display HEIGHT Modifiable The entered value is the pallet height in cm If the value is greater than the real height the machin...

Page 29: ...ble HIGH Modifiable TIMES SUB MENU sec PWM MIN Modifiable Pre set value Allows adjusting the supply power to the up down motor so that the film roll holder carriage remains in position during the reinforce ment revolutions T ERROR 1 Modifiable Pre set value 05 It is the time in seconds of machine movement after which the ma chine stops if the touching arm does not touch the pallet T ERROR 2 Modifi...

Page 30: ...ilm to it Fig 24 Select a work program by pressing one of the buttons MEM 1 MEM 2 etc of the stored programs In the absence of a choice the robot uses the last used program or in the case of re igni tion that of default MEM 1 The number of the used program appears on the display Press START The robot now starts independently moving around the load to be wrapped with constant speed and remaining al...

Page 31: ...pped load The robot waits for the START command to perform another cycle ONLY UP CYCLE It is possible to wrap the load only with upward movement of the film roll holder carriage In this case the carriage stops in high position After having cut the film the operator presses More times to lower the carriage CAUTION TO LOWER THE CARRIAGE TO THE LOW POSITION THE DOWN BUTTON MUST BE PRESSED 3 4 TIMES A...

Page 32: ... check the metal bands of the bump er remove any oxidation check the red mushroom shaped button position CAUTION DO NOT SWITCH OFF the machine using the key or the ON OFF button if the film roll holder carriage is not in low position In the case of only up wrapping after having cut the film lower the film roll holder carriage by briefly pressing the button 3 or 4 times so that it never takes an ex...

Page 33: ...rops too low the supplied battery charger electronic type is unable to recharge them It will be necessary to remove the cover and use a traditional battery charger Each battery must be disconnected and separately powered at 12V Operation to be performed by an electrical maintenance technician 27 USING THE MACHINE continued Operation Film tension adjustment If the film tension is too low the touchi...

Page 34: ...ion boxes and cabinets Competences related to qualified personnel To measure up to the growing need for qualification in the field of maintenance of automatic processing systems the maintenance personnel must mandatorily know the directives in force relating to accident prevention during work performed on ma chines with motorized drive and be able to apply them know how to use and consult the manu...

Page 35: ...Avoid prolonged contact with solvents and inhalation of their vapours Never use water jets in the case of fire on the electrical equipment and use CO2 fire extin guishers Spare parts To guarantee a perfect operation of the system it is necessary that any replacements are only performed with identical spare parts After maintenance before restarting the machine check that Any replaced parts and or t...

Page 36: ... a non aggressive or abrasive liquid we recommend that used for cleaning glass Cleaning of carriage driving wheels Weekly check that there is no dirt or pieces of film jam med in the wheels Fig 28 that may cause the up or down malfunction of the film roll holder carriage If needed accurately clean all wheels Maintenance of competence of the mechanical maintenance technician 28 Quarterly lubricate ...

Page 37: ...heck the effi ciency of the emergency button Fig 30 Monthly check the efficiency of the SAFETY EQUIPMENT Front bumper Fig 31 Motor check Monthly check the efficiency of the MOTORS located inside the machine Fig 32 To remove the body and access inside the machine loosen the two screws indicated by the arrows of Figure 33 MACHINE MAINTENANCE 6 04 32 33 31 Maintenance of competence of the electrical ...

Page 38: ... Fig 34 immediately re place the bulb in the case of malfunction Ground discharge The metal chain shown in Figure 35 allows discharging any electrostatic dis charges to the ground Periodically check that the chain always touches the ground for it to be efficient Otherwise replace it with a longer one 40A Fuse efficiency check If the display does not switch on when the machine is turned on a failur...

Page 39: ...gures 38 Re align the proximity switch by adjusting the distance Correct distance 1 2 mm In the event of failure immediately repla ce them with ITALDIBIPACK original spare parts Photocell adjustment and efficiency check The photocell indicated by the arrows in Fi gures 39 allows reading the pal let presence and the delay of the film roll holder carriage to stop in ascent after the photocell is not...

Page 40: ... With regard to specific extraordinary maintenance interventions on machines forming part of the line in question refer to the relative operating and mainte nance manuals attached to this documentation Troubleshooting The display switches on showing a series of alphanumeric characters and switches off after about 10 seconds The display does not switch on and the ma chine does not work The robot do...

Page 41: ...ting further risks by the environ ment Disconnect the power supply cable of the machine main switch and remove it Disassemble the electric and electronic panels of the machine Disassemble the protections Disassemble the machine in its main parts Separate the system parts according to their nature e g metal plastic etc and send them to separate collection centres Proceed with the scrapping in compl...

Page 42: ...he technicians or fitters provided shall be entirely at the customer s expense The supplier is responsible for defects deriving from normal use of the machine The supplier is not responsible for defects deriving from w problems that occur only after delivery of the machine w misuse of the machine w lack of maintenance w unauthorised tampering or repairs Moreover the supplier cannot be held liable ...

Page 43: ...e request form Company Address We require a service action for the following machine Model serial number Place of service action Contact person Phone Problem Description Electrical Mechanical Notes date Stamp and Signature Messrs ITALDIBIPACK S p A Via Europa 35 20010 POGLIANO MILANESE MI Fax 39 02 93549494 E Mail info italdibipack com ...

Page 44: ...ny Address We wish to place the following order N dated with requested delivery date of for our machine Model serial number Reference Description Quantity Notes date Stamp and Signature Form for ordering replacement parts Messrs ITALDIBIPACK S p A Via Europa 35 20010 POGLIANO MILANESE MI Fax 39 02 93549494 E Mail info italdibipack com ...

Page 45: ...he following European Directives and Harmonised Standards 2006 42 EC Machinery Directive and related national implementation provisions 2004 108 EC Electromagnetic Compatibility Directive EN ISO 12100 2010 Safety of machinery General principles of design Risk assessment and risk reduction EN 60204 1 2006 Safety of machinery Electrical equipment of A1 2009 machines EN ISO 13849 1 2008 Safety of mac...

Page 46: ...Il presente manuale è di proprietà di ogni riproduzione anche parziale è vietata LEO Instructions Edition 01 2016 Revision 01 16 ...

Page 47: ...Il presente manuale è di proprietà di ogni riproduzione anche parziale è vietata LEO Instructions Edition 01 2016 Revision 01 16 ...

Page 48: ...Il presente manuale è di proprietà di ogni riproduzione anche parziale è vietata LEO Instructions Edition 01 2016 Revision 01 16 ...

Page 49: ...Il presente manuale è di proprietà di ogni riproduzione anche parziale è vietata LEO Instructions Edition 01 2016 Revision 01 16 ...

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